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by Chris Kinsfather | Oct 10, 2016 | AC Drives | 4 comments
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Since the primary purpose of a VFD is precise SPEED
CONTROL so that motor speeds can be ramped up and
Blog Categories
ramped down and the connected load can be
AC Drives
maintained at the required speeds, which only utilizes
the energy required.  Knowing this, we wanted to Around the Company

breakdown the tangible and intangible benefits of Back to Basics

installing a VFD. Blog Posts

COVID-19
Controlled Starting Current Engineers Corner

When an AC motor is started “across the line,” it can take up to as much as seven-to-eight times News
the motor full-load current to start the motor and load. This current flexes the motor windings Newsletters
and generates heat, which will, over time, reduce the longevity of the motor. An VFD Drive starts a
Vendor News
motor at zero frequency and voltage. As the frequency and voltage “build,” it “magnetizes” the
motor windings, which typically takes 50-70% of the
motor full-load current. Additional current above this Questions?
level is dependent upon the connected load, the Call us: 847-
acceleration rate and the speed being accelerated, too.
641-2492 or
Email Us at
Bottom line…this extends motor life! 
sales@wolfauto
mation.com
Reduced Power Line
Disturbances
Starting an AC motor across the line, and the Authors
subsequent demand for 300-600 % the motor full-load
current, places an enormous drain on the power distribution system connected to the motor. Beckie Sullivan
When the supply voltage sags, depending on the size of the motor and the capacity of the
distribution system, the voltage sags can cause sensitive equipment connected on the same Chris
distribution system to trip offline due to the low voltage. Items such as computers, sensors,
proximity switches, and contactors are voltage sensitive and, when subjected to a large AC motor Kinsfather

line started nearby, can drop out. Using VFD eliminates this voltage sag, since the motor is started
Karin Wolf
at zero voltage and ramped up.

Lower Power Demand on Start Marshall Wolf

If power is proportional to current-times-voltage, then power needed to start an AC motor across

the line is significantly higher than with a VFD. This will be true only at the start up. The primary Morgan Spano

issue is that some electrical distribution systems might be at their limit during specific times of
day, usually considered “Peak Hours.” When industrial customers start their motors during these Tyler Jensen
peak hours of electrical consumption, it is not uncommon for the customer to be stung
with charges for surges in power during peak periods. These demand factors would not be an
issue with VFD’S.

Controlled Acceleration
A VFD starts at zero speed and accelerates smoothly on a customer-adjustable ramp. Conversely,
an AC motor started “across the line” triggers higher mechanical shock loads both for the motor
and mechanically connected load. This shock will, over time, increase the wear and tear not only
on the connected load but the AC motor as well. Applications that include easy-to-tip product,
such as bottling lines,  greatly benefit from a slow ramp up in power which allows the conveyor
belt to smoothly speed up rather than an abrupt jerk to full power.

Adjustable Operating Speed

Unlike the traditional stop-and-go motor, the use of a VFD enables optimizes a process, by
making changes in a process. This allows starting at reduced speed, and allows remote
adjustment of speed by programmable controller or process controller. Control, in an industrial
sense, is always a big bonus for production!

Adjustable Torque Limit

Use of a VFD can protect machinery from damage and protect the process or product (because
the amount of torque being applied can be controlled accurately). An example would be a
conveyor jam. If just an AC motor connected, the motor will continue to try to rotate until the
motor’s overload device opens (due to the excessive current being drawn as a result of the heavy
load). A VFD, in turn, can be set to limit the amount of torque (AMP/CURRENT), so the AC motor
never exceeds this limit.

Controlled Stopping
Is just as important as controlled (ramped) acceleration, controlled (ramped) stopping can be
important to reduce mechanical wear and tear — due to shocks to the process or loss of product
due to breakage.
Energy Savings
Variable torque loads, such as, Centrifugal fans and pump loads operated with a VFD will reduces
energy consumption. Centrifugal fans and pumps follow a variable torque load, which has
horsepower proportional to the cube of speed and torque varying proportional to the square of
speed, also known as the “Affinity Laws”. Example;  if the speed of a fan is cut in half, the
horsepower needed to run the fan at load is cut by a factor of eight (1/2)3 = 1/8. In trying to
duplicate this advantage with standard inductive motor would require some type of mechanical
throttling device, such as a vane or damper; but the motor would still be running full load and full
speed (full power). Example:  A VFD controlling a pump motor that usually runs less than full
speed can substantially reduce energy consumption over a motor running at constant speed for
the same period. For a 25 horsepower motor running 23 hours per day (2 hours at 100% speed; 8
hours at 75%; 8 hours at 67%; and 5 hours at 50%) a variable-frequency drives can reduce energy
use by 45%. At $0.10 per kilowatt
hour, this saves $5,374 annually.
Because this benefit varies
depending on system variables such
as pump size, load profile, amount of
static head, and friction, it is
important to calculate benefits for
each application before specifying a
VFD.  Savings of a VFD can be
sufficient which would allow for
shortened payback period.

Reverse Operation
Using a VFD eliminates the need for a reversing starters, a VFD allows electronic ability reversing
either by integrated reversing or an external switch added to the VFD terminal control board.  The
elimination of a reversing starter eliminates its maintenance cost and reduces panel space.

Elimination of Mechanical Drive Components

Using a VFD Drive could potentially eliminate the need for expensive mechanical drive
components such as gearboxes. Because the VFD can operate with an infinite variable speed, it
can deliver the low- or high-speed required by the load, without a speed-increasing or reduction
devices between the motor and load, of course this is application dependent. This eliminates
maintenance costs, as well as reducing floor-space requirements.

Still curious about how incorporating a VFD could benefit you? Take a look at our “Making
Greywater Greener” blog which dives further into the benefits of including a VFD in any
wastewater treatment center. You could also check out our helpful blogs on “Basic VFD
Programming Tips“, “What is a Drive?” or “Phase Converters vs. Variable Frequency Drives”
to learn even more about VFDs and their benefits.

If you’re ready to take advantage of installing a VFD for your application, contacts our sales team
or tech support today and we’d be more than happy to help you with sizing, price and availability!

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Chris
Kinsfather
4 Comments
Brow
n on July 2, 2017 at 3:17 am Reply
Thank you for this well explained article

arun
shanakr on September 18, 2017 at 9:53 am Reply
very excellent explanation which can be
understand by every one.

Shahba
z on March 6, 2019 at 12:47 pm Reply
Excellent. Thank you a lot for this Chris!

vikes
h on February 11, 2020 at 11:58 am Reply
I have never seen such a good explanation

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